Vincent g



June 7, 1927. 1,631,186 v v. G. APPLE METHOD OF BUILDING DYNAMO ELECTRIC MACHINE ARMATURES AND WINDINGS FOR SAME Filed Sept. 22, 1924 3 Sheets-Sheet l Fl .4 l W 7 I l 5 A50 .3 i i L t 52 54 i 53 5Q F197 H /0 Fig. Fi /2 Fi /3 Fig. /5 Fig. /6 aw 3 2 7/ I Fig. 52 a 6/ Fig. 2/ 5 Fi 42 2/67 Fig. l? 5/ IIIVVENTOR June 7,1927. 1,631,186

V. G. APPLE METHOD OF BUILDING ammo ELECTRIC MACHINE ARMATURES AND wmmucs FOR sms Filed Sept. 22, 1924 3 Sheets-Sheet 2 F1422 Fig.2.?

INVENTOR.

June 7, 1927. 631,186

V. G. APPLE union or BUILDING ammo ELECTRIC momma ARMATURBS AND wmnmcs FOR sum Fileq Sept. 22, 1924' :5 Sheets-Sheet 3 Fig.34

7 .37 .52 Fig.38 5

INVENTOR.

Patented June 7, 1927.

UNITED STATES ear-186 PATENT OFFICE.)

VINCENT G. APPLE, OF DAYTON, OHIO.

METHOD OF BUILDING DYNAMO-ELECTRIC MACHINE ARMATURES AND WINDINGS.

FOR SALIE.

Application filed September 22-, 1924.

This invention relates particularly to methods of building armatures of the type comprising a core, a commutator and a bar winding and while in ordinary practice a 6 commutator bar must be joined to each turn of such a winding it is an object of this invention to provide a structure a single unit whereof comprises a commutator barand a turn of the winding integral, to the end that the cost may be reduced by decreasing the number-of" parts, the electrical circuit improved by eliminating some of the joints, and a finished article provided which will be more durable and dependable and of better appearance than when made by present methods.

Other objects will be apparentto those skilled in the art as'the invention is described indetail and reference is'made to the drawings wherein- I Figs. 1, 2 and 3 show several partially completed forms of my commutator bar and winding turnf 1 Figs; 4 and; 5 are cross sections taken through the commutator bars, and either cross section shown may represent a section taken on a line 0bof'Figs. 1, 2 "or-3.-

Figs. 6, 7 and 8 show. meth'odsof increasi'ngthe thickness of acommutator lugto compose a commutator segment. 1

taken through the winding legs. and any one of the cross sections shown may represent-asection taken on a line 'wt of Figs. 1, 2 or 3.

Fig. '14 shows one form of cutter which I may employ to separate the bars to form the two legs of a winding turn; 7

Fig. 15 shows how a bar of across as in Fig. 5, appears when out apart by a cutter such as is shown in Fig. 14.

Fig. 16 shows how the sharp corners of the bar shown in Fig. 15 may be rounded by striking'in a die.

Fig. 17 is a cross section through a bar particularly suitable where limitations in armature length are imposed.

Figs. 18 and 19 show how a bar of across section shown in Fig. 17. is split and bent to compose a commutator bar and winding turn.

Figs. 20 and 21 show how a bar of uniform cross section throughout its entire length may be upset'to provide a commutator bar and winding turn suitable where Figs. -9 to 13 inclusivearecross'sections section.

Serial No. 738,998.

limitations in armature length are imposed. Figs. 22 to 25 inclusive show some of my winding units inserted in the slotsof' an armature core. 9

Figs. 26 to 31 inclusive show means which I employ to bind the segments together to form a commutator therefrom. Fig. 32 shows a bar which has been both cut to length and split by a cutter such as I Show in Fig. '14.

Fig. 33 is an end view of the bar Fig. 32. Fig. 34 shows how the bar Fig. 33 is bent to provide a commutator smaller than the armature core. v

Fig. 35 shows how the bars are notched to form projections upon-which a binding means may bear to bind the segments together to compose a commutaton Fig. 36 shows the bar=after-the conductor legs are spread apart sufficiently 'to compose a winding turn. r Figs. 37 and-38 are cross sections taken on lines 37-37 and 38 538 ofFig.36. 1

Fig. 39 shows a number ofunits Fig: 36:

asscmb'ledon-ia core. I!

Fig. 40 shows .one pair of the-openends circuit.

Fig. 41 shows a? completed armature,

provement applies vary considerably in sev eral of their proportions, as for instance an armature'of a given diameter mayhave in one case a commutator of'the same diameter as the core. and in another casea commutator of half the diameter of'the core.- "The apertures or slots in an armaturecore into which the conductors are laid vary considei"-= ably in contour,- and to usec'onductors'of' maximum capacity in a glven slot the'con tour of the conductor must closely conform to the contour of the slot. The proportion of the core slots relative to the intervening space commonly called the core teeth. varies considerably the circumferential extent of a slot ranging from half to double that of a tooth. In order that my'invention may be more universally employed it is therefore brought together'imd joinedto' complete the necessary that considerable variation may be had in both the cross section and outline of my Winding turns. I 1 I When applying.- my winding to. an armature having a commutator of substantially equal diameter to the armature core I start with a blank 'as shown in Fig. 1 where a bar has been sawed or otherwise split, 2L3 at I 50, providing a leg 51 which later becomes aconductor of the outer layer of the winding, a leg 52 which later becomes a con ductor of the inner layer of the winding and a. portion or lug 53 which laterbecomes a segment of the commutator. \Vhen the commutator is to be considerably smaller relative to the core the blank may be as in Fig. 2 and when very much smaller it may be as in Fig. 3, the bent portions 54 and 55 of the conductor bars being brought to the form shown by bending a blank likev the one-shown in F ig. 1, or the blanks F igs, 2 and 3 may be so cut from? a. sheet or be otherwise fabricated to proyide forms as shown. 3

I A cross-section taken-through a-comrnutator bar on lines cb, Figs. 1, 2 and 3, is preferably as in Figswtorb. Since the spacers of mica or otherinsulating material usually-employed bet-ween bars of a com 30 mutator are usually taken from.-fiat=sheet stock Ilta'fOllOSVS that: a: wedge shaped cross section as shown-is. most suitable fora com mutator bar. When the commutator is to bev of a diameter substantially that of the 36 armature corejjtisbbvious-l that the commutator; bars must; be considerably =thi cker'than the conductor legs sinoerthew insulating spacers-between the commutator bars. are thinner-Ethan. thei'core; teeth which separate the conductor legs in the finished armature. Suclm-m conditionumay: be=-meft in several ways. For instance, I may use ii-dra'WnE bar of such cross section as to besuitable without change for the desired commutator: seg

mentand, after splitting as inwFig. 1,"form conductor legs ofthinnebcros's section by, striking. in a die, ortotherwisefabricating the split portions to the desired thinness and contour, or'I may-usea drawn bar'of suchsize and cross section as .tOube suitable, after. splitting, to form the conductor legs without. further change and. then 1 increase the thickness .of the commutator lugeither. by. striking it=edgewise in a-jdiezLbyupsetting. orabyaddinga .U-shaped-st-rip of metal, as at 56,-Fig. 6, or by adding-a. pad to the side ofeach commutator lug 53, asat 57, Fig; 7, or at 58, Fig. 8. Y VVhen apad is so added to the side of 'each'commutator lugit may be joined thereto by soldering brazing .or welding, or it may be notched in a manner similar to its corresponding: commutator lug so that the means employed to bear on" the notched portions of the commutator lugs to bind the commutator together will also hold the pads in proper position in the com pleted commutator. The manner of notching...th ,comnuitator lugs to,,pr,p vide projection siwheieon the binding mefinsma y bear is shown in Figs. 26 to 31 inclusive and will be later described.

For coinmu ta tors of relatively large diameter as, compared 10- ,tl1Q, ljal] 1QtlY- gtl tl e armature core this method of padding "out the commutator lugs to compose commutator segments oflersmany advantages, as. for instance, when the slots in 1. core require that the'cross sectiorrof' a pair of conductor legs be as'in Figm9, a punching of suitable thickness and-:of the form-shown in :Figul:

may betaken fromfiat sheet Stock and a pad comprising oneor .even more:.layers may be added'to .the side of lug 53, 115 at- 58,-Fig. .8,.the paddingtbeing. of such: cross section as to make-the composite crossse'c tionof lugand .=p ad:.simil'ari.to-.the cross section.Fig.--=4'.and ot-a sizeqsuiteble for the m i tor .ofian ai-meturetbe considerable Inn smaller thaw-the;armature more andin such.

casesat is usuallygpossibletoso proposton' the scoige 'filotsnthat audrawnisbar of wedge shaped oross seetiom as) inm'F igsn 4,-i01'- ;55 bent and split as, inwl lifla QuiYiJJ, with .little. orhnos change. in; cross ectiol'l gilt any point, be;-. adapted to congpose a commutator .--.se,' *i ment al .rd..-two; conductorwlegsd integrail 1 as howm EB Q t form is. leMl-ily bta n b e fii n saflfim llfilclfilly produced in varying wedge angles ;f0ll use inmaking: commutators of theuconventional typeij .111; many cases therefore; a suitable proportion of r mutaterd am e etenccre sliame ma will be had: when; stools-of; .tlie :crosssection of. Figs-,4. or is.-,cut,.apart,-, to, .form; coinu m egs, a -.=51: and 52: Fig. 1.0,. or. at 51 and 52, Fig. 11, andg the core slots proportioned-{t0 receive each a pair, it-such g with no; change'in -cros 3,- section therein. the bar either beforeor afteiysplitting being bent;-as at--54; and 55,F-ig.;2.:: a

A form fgeore slot much-used is one of wedge 5 shape but, rounded. .both at. its .outer and inner ends and for such a slot the con-- ductor legs-Would preferablybe sh aped-a's ta 1' 51and 52, FigJ lQA'j'It1tzi5fqth6llyQptiQllHl Whetheri-d split.- a..--drawnbar,i such asisshowningFign, and round-the :top edge of:

; mutator segment as ,in Fig. 5.

the outer conductor leg; 51 as'in' Fig. 12 to conform to such: slotor adrawn =bar formed as in Fig. 12 and flatten the thicker rounded outer edge: Where required to provide a coml-Vhen the core slots are bestjadapted to receive conductor legs as at 51 and 52, Figs. 9 and 13 and a commutator considerably smaller than the core is desired I may cut a blankas in Fig,- 3 from flat sheet stock and strike the lug 53 fiatwise to bring it to-the wedge shape necessary for a. commutator segment. v

For cuttingotl andgsplitting bar; stock; Y form-my winding units 1 may. employ asa preferred; method a-zpainof cutter bladesas shown'in Fig. 1-'l where the cutting edges 59 come together to separate a b3l30f theform. shown in Fig. i-nto..parts;5l and ;5.2, as shown .in vFig. l5.-.- -'By.nsing this form ,of, cutterno burrslare produced at theouter edges of the. conductorswhere they Ema in? terfereg with entryinto the core slots. -A bar so cut may, when spreading the;coi1t luo-- tors apart to loop or ,;-,be struck-,in aj'die I to slightlyi round all-psharp--edges of the conductorsfil aud 5 2to bring themto the formshoyvnat 51and 52,:Fig2l6. 5. 'lo provide an armature having zucommu-i tatorlextending 'ag minimunr/ distan ce =-out..

having a;cross =secti0n;;as.in- Fig li -and, to. provide; two, conduotoijlegs cutit .a part; on: the. liue .a-jb-.fj.;lVhen' first so' out apart the bar-will appean as in -Fig.-.l8, thejnneb-legi 52..being; thioker t-han the itglltel' rleg-nslgai reforming has :a cr'oss: section-as iz fi" :1 .To. accomplish-a. Sllllllzll': rcsult Iin'ialengthgof banstockof It-Cl'OSSSQCtlOll-HS- at. 52, Fig. 13,}ancluipsetia. portion nearithe;

middle to provide alconmiutator segirientaas. at 61. Fig. 20. after which Lnia' y :lie'nd thei lengthfas at 62, Fig.-: 21, and then spread apa rtthe legs. inra nianner' 'sirnilar to-Fiig..

. 19. A -cross,sect io n through conunutator= is. sh Wnin-FigZAZ -J 4 i o, 1 .51. As anotheumeans of providing afcoinmuv tatorg;inunediate'ly;,achaeeuti the: .core. lmay segmentfil-anttouter leg 51 taken at- 12 12:

a use a lengtlrot'; bar-stock th cross section us at 52. Fig. l and bend it lirst-asuat (32,: Fig. 21,-then spread apartyt he legs in' a manner jsimilar to Fig. l9vand-provideza thickened portion as zit-61,;Fig..20;by-add- 5 mg; aypadiat -thispointfthcipadubeing of to: i

such size-'andcross section as. added to-"the bar will provide the necessary segment.

It is obvious that a- Winding unit .so formed will provide a commutator immediately adjacent to the core whereas ordinarily the commutator occupies a position: considerably removed from the core and while I- here show a. :unitadapted towform an in-' ternal commutator it apparent that with: slight. modification of thewcromwsectlon shownin F ig; 17 an external commutatormay be provided. if,"

In Figs. 22,- 23, 24 and-- 5 vI.--show-how=the winding; units shown in Figs. :1 ,"2,. 3 and18 respectively appear after the; legs are' spread apart and insertedtinzthe slotsiof=m core, the outer conductor .legs occupying a posi-- tion in the outer half of a'oore slot and" the inner legs a position in-t.he- ;inner. half: 'of a; core slot." The commutatorilug 53 ocoupies in Fig. 22 a positionzadapterl'torprovide' :r commutator substantially:- as' large as." the core,- in Fig. 23 a commutator eonsi'tlerablyr smaller than the Tcore' 'an'd? lgl24 areomf-g mutator very much smallerilthant theeooge:

The commutator lug; 6D, 25, ceupis" a position adaptedto provide ans'egment Ofi internal com'mutatori'; To dug f53yF'igg 22, toi a thickness siiificiepb fom'zricommutaton segment a, pad isi-prefrablji add'edigthereto i i as; shown inland destribednrlahiviai-io:diigz; 7, the pad being .oiaithicknessisubstahtially that, of a.=c orel tooth 63. l flotbtinggylligrfil y Fig; 24, tois'uitableicrosgwectitmjforgi- 'com-.: mu tatorsegment it" may: rbe struoki flatwiss in a, dieitol bringit; o theni'edge' s'liaped'sec-f lO IMS Q-Efi'. "fiiioltic-ki-rw several; {formsnvh'iclr may: takeand; severaluxdethodsjz i ia e'ip'meys re sue, 1:0 prbviglesam'k-i-m!aceordahe (with iny; invention; :consid'rable ivaniatiohtiru both the articlewancl {met-bode magrl'benallmvemitvifiing the;=-"scope.: :o-fi'the- .in ventiomiashforl instance \v-heieas-imFigs' p I l g Y the conductors of?) aioopft-ihregsprea doapa rt to. compose a; winding tnrni'aeli' corlductor 3 being: circuniferentially bdis'plaeed Egequallj from the commutator segmentJ'theyl may; if 0 desired! be-dis'plaeedwt-he lone rrfor'eithaii the other; :the object'beingmerely to's firead -thelegstsuflicientljrl to" compose auturn gofflthel winding which iisi' usuallyer'abouti 90116 13015 pitch and while'l desonihearilethodsiiof va riously: producing theii wi-nding i uni-ts fromj bar stock or. from; flat i sheetsldt i-is-f-tb un 1 derstood that: Ivcons'i-der ianyiiwinding unit of-- the 'charactershowni to'zcouie witliimthescope ofzmy' invention:xvhetheiiit'is.so made or i whether: itis forgeclysah ddie east or o.tlierwise fabrieated to bringnit td the form'si snownz or to' similar :forrns fl vithin the t ofthe inve'ntion zl ff then a; plmalityP-ofi win d irig u ni-ts ar assembled! .to compose: ianfii integral-' commu tator and winding, a means of binding the several commutator segments together must beprovided, and in Figs. 26 to 31 inclusive I show several methods by which I accom plish this end. In Fi s. 26. 28 and 30 the commutator lugs are t irst cut as at 64, 65 or 66 then after assembly the structure is placed in a mould and fluid insulating material 67 is poured or pumped into the mould to surround the lugs as shown and then hardened or allowed to harden by heat or otherwise to form a solid mass which binds the lugs together to form a CO1lll1lU- tator. In Figs. 27, 29 and- 31 the lugs are 7 cut somewhat dili'erently and tie segments bound together in a manner similar to that used in common practice in commutator building where notch-es are so cut as to leave points on the lugs as at GS and (39 oppositely extending, insulation as at 70 covers the notched portions of the bars and conical washers as at 71 and 72 are drawn toward each other at opposite ends of the notchec portions by a nut 73 to bind the commutator segments together; v i

Bars of the type shown in Fig. 19 after being assembled in acore as in 25 are preferably bound together'by the moulding method described especially where an'internal commutator is 'desired'as then there is ample space around the bars for a heary ring of insulating materiaL:

In Figs. 32 to 41 inclusive I more clearly show by several steps'one' method I employ to complete an armature. Barstocl r of a cross section as shown inFig. 5 is-cut into suitable lengths and split by cutting blades as shown in Fig. '14 to provide bars 51 and 52 as shown in Fig. 32 andin its end-view Fig. 33. The bars are'then bentas at 54 and 55 to the form shown in'Fig. 34. =Next they are notched as at 62, Fig. to provide projections upon which moulded insulation used as a binding means may afterward bear to bind the. segmentsfltogether into a commutator, though, if desired, the bars may be notched as in Fig. 29 leaving points 68 and 69 oppositely extending and the commutator may be bound together by the conical washers 71 and 72 and thelnut 73 as therein shown. form open end loops as in Fig. 36 and at the same time the conductor legs 51 and 52 are struck in the die so thatthey will have a cross sectional contour as at 51 and 52, Fig. 37, leaving a commutator segment having a cross sectional contour as at 53, Fig. 38. A number of such loops corresponding to the number of slots in the core 74 are then stacked in cylindrical formation with the free ends of the conductors slightly entered into the core slots then simultaneously endwise entered in the core. For clearness of illustration in Fig. 39 I show only a portion of the winding units assembled with the core round the entire winding as shown.

Next the legs are'spread apart to but it is obvious that the entire required number may be thus entered at one and the same time. As the method of assembling a complete set of conductors and pressing them simultaneously into the slots of a core, bending the free ends simultaneously to form pairs and joining the pairs by welding or otherwise to complete the circuit has been made the subject of prior claims no extensive description of this portion of the method is herein contained.

Some of the methods used in common practice may be employed such as placing spacers of insulating material between the commutator segments, and insulating linings in the core slots. \Vhile I herein show a core having partially closed slots into which the conductors must be endwise entered itis apparent that such conductors may be similarly entered into slots which are entirely open or entirely closed or they may be radially entered one at a time in a core having open slots.

"Fig. shows only'one pair of the free ends of the conductor bars 51 and 52 and how they are brought together and joined as at 75 to complete the circuit, the manner in which they are'bent and joined being typical of the entire winding. The joints may maintained by welding, brazing, soldering or otherwise, welding being a preferred method, the two ends being shown after welding at 76, Fig. 41, but while I have herein shown and described this method of joining the free ends of the winding bybending the ends to form pairs as in Fig. 40, it is obvious that, the older method of using separate end connectors of involute or other form maybe employed if so desired.

;In Fig. 41 Ishow a, complete armature partly in section wherein I employ welding as at 76 to complete the winding turns and moulded insulation 67to bind the commutator=together in the'nianner described relative to Figs. 26, 28 and 30, the moulded insulation being here further employed to sur- It is however equally practicable, when the commutator bars are appropriately notched, to bind this commutator together by the other method shown in and described relative to Figs. 27, 29 and 31.

While in Figs. 32 to 41 inclusive 'Ihave out-lined steps whereby one form of my invention may be put into practice, it is obvious that the steps described need notnecessarily be carried out in the order given since with proper tools and equipment several steps may be combined into asingle operation and while I herein indicate that the winding is to be assembled with the core prior to binding the segments together to form a. commutator, it is obvious and it may be preferred that these winding loops be stacked in cylindrical formation and the thiis"c'ompose a complete commutator with winding "integrally attached which may be afterward en wise" enteredl-into the'core slots and properly joined at thejfreeendsto, com-- plete the circuit. jI-fam aware that prior to this-' -invention-"armatui's have been built having as their winding, loops, each comprising one turn, assembled in a core, their free ends bent and joined in pairs and attached to separate commutator segments, or paired one with another to form commutator segments. An important difference therefore, between this and prior methods, consists in having a complete commutator segment integral with and at the closed end of the loop.

Having described my invention, I claim:

1. As an article of manufacture, a commutator segment having two armature conductors integrally extending therefrom.

2. As a turn of an armature winding, an integral unit comprising two conductors joined in the form of a loop open at one end and closed at the other, the closed end being extended to compose a commutator segment.

3. As an article of manufacture, an integral unit of an armature winding comprising a commutator segment and two armature conductors, all of wedge shaped cross section, the conductors being spaced apart to compose one turn of the windin 4. As a unit of an armature winding, '3. commutator segment havin two armature conductors integrally extending therefrom, one conductor bar being of suitable cross section and form to occupy the outer half of a core slot to compose a half turn of the outer layer of an armature winding, another conductor bar being of suitable cross section and form and positioned relative to the first conductor to occupy the inner half of a core slot to compose a half turn of the inner layer of the armature windin and said segment being so positioned relative to the'conductor bars as to form one segment of the commutator.

5. The method of making a unit of an armature winding, which consists of cutting off a length of commutator bar stock and longitudinally splitting the same from one end to a point somewhat removed from the other, with U-shaped cutters which, cutting inward from both sides, leave no burrs at the outer edges, bending the bar so that one of the split portions may occupy a position in the outer layer of the winding, the other split portion may occupy a position in the inner layer of the winding and the unsplit portion may be in a suitable position to compose a segment of the commutator, notching the unsplit portion to provide means whereon a connnutator binding means may bear and spreading apart the split portions sufiiciently to compose a winding turn.

6. As a turn of an armature winding, a single i'ece of conductive material in the formo a loop, open at one end and closed at the other, the' legs of the loop being of suitable form'to compose two conductor bars of the winding, and the closed'end being so formed as to provide thereon a suitable comimitating surface.

7. As a turn of an armature winding, a li-zu' of wedge shaped cross section, longitudinally split from one end to a point somewhat removed from the other, the split portion being spread apart to compose the two conducting bars of the winding turn, and the unsplit portion being of suflicient length and suitably positioned relative to the conducting bars to provide a commutator segment.

8, In a dynamo electric machine armature, a core having a plurality of winding apertures, a plurality of winding turns each com- ;osed of a single piece of conductive material comprising two conductor bars of the winding joined at one end and suitably formed at said joined end to compose a commutator segment, insulating spacers separating said segments, and a binding means to bind said segments together to form a commutator, said segments bein provided with projections whereon said bin ing means-may bear.

9. In a dynamo electric machine armature,

' a slotted core, aplurality of winding units vided with projections whereon the insulating material may bear.

10. The method of making a dynamo electric machine armature, which COXISlSlSOf providing a slotted core and a plurality of wedge shaped bars of conductive material, longitudinally splitting each bar from one end to a point somewhat removed from the other, spreading apart the split portion of each bar to compose the two conducting bars of a winding turn, and suitably positioning the unsplit portion of each bar relative to said conducting bars to compose a commutator segment, notching said segments, assembling the winding units thus rovided with the core, joining the open en s to complete the circuit, and molding insulating material thru and about the structure to bind the segments together.

11. The method of making a commutator and winding for a dynamo electric machine armature, which consists of providing a plurality of bars, longitudinally splitting each bar frem one and to a point somewhat re- 'ide means whereon a, eommutator binding moved from the other, spreading the split means may bear, assembling said plurality 10 portion sufiiciently to compose the two con 9f bars incylindricel fprmation, and appl (letting bars of a winding turn, suitably g mmutator bmdmg means.

positioning the unsplit portion, relative to In testimony whereof I hfllelmto Set y.

Said conducting bars, to compose a commuhand this 9 h day of Sept, 1924. tator segn'lent, notching said segment to pl 0- VINCENT G. APPLE. 

